I was excited to find your thread -- no one else seems to have done a "shell-on" total floor replacement. I started on my 1959 Overlander in May, am trying to get it ready to live in by Sept.
My goal in doing it shell-on was to save time, but I'm not at all sure that's going to be the case. Like you apparently did, I wound up having to trim my belly pan WAY back, really need to replace the whole thing now, which means somehow un-riveting and re-riveting the whole @#$% shell!
At the moment, I have a new sub-floor pieced in and bolted to the frame, but haven't done any of the perimeter yet. I'm having a problem getting the shell lined up properly with old holes in outriggers and wheel-well covers. It's as though the whole shell has crept forward on the frame ever so slightly, a bit more on curbside than street: something < 1/4" on one side,< 1/2" on the other. It's attached at the vertical plate in front, otherwise has been floating like yours was, with a few bolts at outriggers to tack it down, until the sub-floor went in.
I'm hoping that you, or one of the other helpful folks on this thread, may have a magic solution? Or at least some good ideas to try?
Getting all-new electrical in Monday, then I'll get all-new running gear installed (by local horse trailer place) as soon as I have it bolted back together and mobile.
After that, someone (and I hope it's not me!) needs to fit the sheet-metal to the belly and buck-rivet the perimeter. Are you planning on doing this yourself? Uwe ALMOST has me convinced that I can -- but having recently seen his fabulous re-done 1963, his skill levels are clearly considerable, so I'm not sure his idea of "easy" and mine are the same!
After that, someone (and I hope it's not me!) needs to fit the sheet-metal to the belly and buck-rivet the perimeter. Are you planning on doing this yourself? Uwe ALMOST has me convinced that I can -- but having recently seen his fabulous re-done 1963, his skill levels are clearly considerable, so I'm not sure his idea of "easy" and mine are the same!
Lynne,
Do I really have to come all the way back to show you how easy it is to buck rivet? You can bring tiny, fragile humans to this world - how could you shy from something as barbaric as buck riveting? You basically brutally smush a soft shaft of aluminum by means of air pressure and piece of steel. Basic. Requirews a little practice, but the learing curve is steep and fast.
I can send you my riveting stuff on Monday, if you PM me a shipping address. Try it on a piece of belly pan and see how easy it is. Do you have an Air compressor? A smallish one will do for riveting. Be brave - go rivet something!
Welcome back after a hearthside absence! The '58 Overlander looks very very sweet, a beautiful trailer with stunning lines and just-the-right windows. I'll be following your progress from a bit north and cheering you on. Good to see you again.
__________________
Fred Coldwell, WBCCI #1510, AIR #2675
Denver, Colorado - WBCCI Unit 24
Charter Associate Member FCU
Vintage Airstream Club Historian
Airstream Life "Old Aluminum Adventures"
Its really scary knowing the whole shell is only attached in the front - I had visions of the thing falling on me and never being found again
I did keep some bolts loosely in to keep things lined up, however, still had some adjusting to do - it took a bit of brute force, but I did get it all lined up - I then used stainless steel bolts, lock washers and stainless nylocks - hopefully that will keep it where I want it.
How far did you cut the belly back? Do you have any remaining belly that you can use to attach a new belly? I did end up putting all new belly along the sides of the trailer - because the old was in terrible shape - I left the original belly in front and back - seems like that would be hard to replace with the shell on process - the sides is not bad at all.
YES! you can do it - I also had the buck riveting fear - Its easy and fun - the only thing that you have to make sure is that you have the air hammer firmly on the rivet - otherwise it can slip off - if the truth be told - I bucked about 10 rivets as practice at the most before I went for it on the trailer - had 3-4 out of 100's that I mess up on - my wife and I did it together - she holds the bar and I do the gun - a $10 harbor freight gun I might add.
This forum and the VAC forum got me through this restoration thing - it will get you through it too - sooooo keep asking away!
Thanks! Yea I miss seeing y'all last 2 years - got into this rebuild thing (vs restore.... ) and have spent more time under the thing rather than in it camping - which I would much rather do - I think I'm back on the road for sure this fall, so you we be seeing me.... It was a total disaster when I got it, but since it is the same as my wifes birth year - she said "you can do it" - if I had any idea it was going to take 3 years - I would have said "no way" - is fact I did say "no way" at first, but then I figured what the hey.......so the only thing that will be original will be the frame and shell.
Arent' those windows cool? I bet you have never seen or ever will see that on another trailer - As I 've figured out you can look at the windows on the 57 in RJ's site and you will see the exact same window openings - sometime early in its life, they were replaced with what I have - or special ordered from the factory - I know back then you could get pretty much what you wanted...
I've got about 85% of the interior finished - at least enough to take it out for a test camping trip - ordered custom mattresses - so should be good to go here in a couple of weeks - first real camping trip will be over labor day weekend.....
Ken, It is looking good! Glad to see that you are getting ready to hit the road again. I know that it has been over a year for you. I am sure we will be camping together in the near future.
Good to hear of your progress from a new location. As AZflycaster said, we look to be camping with you guys soon. Keep up with the work and pictures of your progress. Looking great Ken.
I've got about 85% of the interior finished - at least enough to take it out for a test camping trip - ordered custom mattresses - so should be good to go here in a couple of weeks - first real camping trip will be over labor day weekend.....
Ken J.
I keep telling myself that I'll be there one day, actually putting the interior back in. It's hard to believe!
So, did you end up refinishing that interior wood, and if so, what technique did you use? Is there a veneer on that wood?
I can tell you from personal experience that this is a very rewarding phase when restoring an old Airstream. After month and month of prep work, riveting, painting, welding and general nonsense, putting in the interior suddenly makes all the nasty memories disappear.
Great progress, Ken!
Yes I can relate to wondering if I was ever going to get here - look at the earlier posts for interior pictures and you will see what I mean....
What you see is a complete rebuild of the interior - the original interior was trash and basically fell apart when I took it out - I was able to use it for patterns however.
Yes this is finally a rewarding phase - I can see the end of the tunnel - it has been a lot of work for the past 2 1/2 years.
Putting the interior in was not totally fun though - since I used the old as patterns, sometimes things did not fit as exact as I would like - hanging the overheads was a bear when I tried to used the original screw holes - I finally drilled new holes - much easier -
So now its ready for its first short trip - had to admit I'm a little uneasy after all of this that the exterior rivets won't pop off, axles, springs and wheels don't fall off or ride too rough, the paint doesn't peel off the interior, the upper cabinets don't fall off - etc etc etc..... I'm not counting on much sleep the first night.........
I used birch plywood and poplar facing - if I had to do it again I would have used birch facing - its hard to find good clear poplar.
Yes for sure we will be camping with guys again - I can't believe I've been out of it for so long - I really miss seeing all my Airstream friends! However, we are back! and looking forward to lots of time "in" the trailer rather than "under" the trailer
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Good to see you again. 
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